B4000 SE Cab Plus 4WD V6-4.0L OHV (1997)
Shifter Transfer Case: Service and Repair
REMOVAL
1. Place the transfer case in 4L.
2. Remove the shift ball, referring to the following.
a. Remove the plastic insert from the shift ball.
b. Heat the shift ball with a heat gun to 60 - 87°C (140 - 190°F).
c. Knock the shift ball off the shift lever with an appropriate U-shaped tool.
3. Remove the rubber boot and floor pan cover, referring to the following.
a. Remove the screws.
b. Remove the rubber boot.
c. Remove the bolts.
d. Remove the floor pan cover.
4. Disconnect the vent hose from the control lever.
5. Remove the shift lever, referring to the following.
a. Remove the nut from the shift shaft lever.
b. Remove the two shift lever bolts.
c. Remove the shift lever and bushing.
INSTALLATION
Install in the reverse order of removal, referring to the following notes:
Shift Lever
1. Loosely install the shift lever onto the extension housing.
2. Install the bushing with the flat facing out.
NOTE: Lubricate the bushing and pivot bolt prior to installing the shift lever.
3. Install the shift lever onto the shift shaft lever.
4. Tighten the nut to 26 - 35 Nm (19 - 26 ft. lbs.).
5. Adjust the shift linkage.